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“Designed by clowns who in turn are supervised by monkeys” – that was the view of the 737 Max from one Boeing employee in 2017.
The comment, whose writer also describes the plane as “p*** poor,” is among hundreds of emails and text messages released to regulators and the US congress. They provide shocking evidence of Boeing’s efforts to keep the costs of the 737 Max down by dissuading airlines that simulator training would be needed.
The twin-jet has been grounded for 10 months since the crash of Ethiopian Airlines flight ET302 on 10 March 2019. All 157 passengers and crew died after the pilots lost a battle against new flight control software that was forcing the nose of the plane down.
The software, known as MCAS, was also implicated in the first crash of a Boeing 737 Max in October 2018. All 189 people were killed aboard a Lion Air jet that crashed shortly after take off from the Indonesian capital, Jakarta.
Now Boeing has published more than 100 pages of text messages and emails provided to the Federal Aviation Administration (FAA) and US congress investigators. They reveal a concerted campaign to deflect calls for flight simulator training.
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This picture taken on March 11, 2019, shows debris of the crashed airplane of Ethiopia Airlines, near Bishoftu, a town some 60 kilometres southeast of Addis Ababa, Ethiopia. - An Ethiopian Airlines Boeing 737 crashed on March 10 morning en route from Addis Ababa to Nairobi with 149 passengers and eight crew believed to be on board, Ethiopian Airlines said. (Photo by Michael TEWELDE / AFP)MICHAEL TEWELDE/AFP/Getty Images
AFP/Getty Images
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Family members mourn the victims at the crash site of the Ethiopian Airlines operated Boeing 737 MAX aircraft, at Hama Quntushele village in the Oromia region, on March 13, 2019. - A Nairobi-bound Ethiopian Airlines Boeing crashed minutes after takeoff from Addis Ababa on March 10, 2019, killing all eight crew and 149 passengers on board, including tourists, business travellers, and "at least a dozen" UN staff. Families of the victims were taken to the remote site on March 13, 2019, where the plane smashed into a field with 157 passengers and crew from 35 countries, leaving a deep black crater and tiny scraps of debris. (Photo by TONY KARUMBA / AFP)TONY KARUMBA/AFP/Getty Images
AFP/Getty Images
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A page of a Boeing flight crew operations manual is seen at the scene of the Ethiopian Airlines Flight ET 302 plane crash, near the town of Bishoftu, near Addis Ababa, Ethiopia March 12, 2019. REUTERS/Baz Ratner
REUTERS
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epa07434278 Rescue workers search the site for pieces of the wreckage of an Ethiopia Airlines Boeing 737 Max 8 aircraft near Bishoftu, Ethiopia, 13 March 2019. Ethiopian Airlines flight ET 302 carrying 149 passengers and 8 crew was en route to Nairobi, Kenya, when it crashed on 10 March 2019 by yet undetermined reason. All passengers and crew aboard died in the crash. The Boeing 737 Max 8 aircraft has come under scrutiny after similar deadly crashes in Ethiopia and Indonesia within a few months. Several countries have banned the plane type from their airspace and many airlines have grounded their 737 Max 8 planes for safety concerns after the Ethiopian Airlines plane crashed minutes after take-off on 10 March. EPA/STRINGER
EPA
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A grounded Boeing 737 MAX 8 passenger plane of the Norwegian low-cost airline Norwegian is parked at the tarmac at Vantaa airport in Vantaa near Helsinki, Finland on March 13, 2019. - A number of countries have banned Boeing's 737 MAX 8 medium-haul workhorse jet from their airspace in response to the Ethiopian Airlines crash that killed all 157 people on board. (Photo by Heikki Saukkomaa / Lehtikuva / AFP) / Finland OUTHEIKKI SAUKKOMAA/AFP/Getty Images
AFP/Getty Images
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Rescue workers search the site for pieces of the wreckage of an Ethiopia Airlines Boeing 737 MAX 8 aircraft near Bishoftu, Ethiopia, 13 March 2019. Ethiopian Airlines flight ET 302 carrying 149 passengers and 8 crew was en route to Nairobi, Kenya, when it crashed on 10 March 2019 by yet undetermined reason. All passengers and crew aboard died in the crash. The Boeing 737 Max 8 aircraft has come under scrutiny after similar deadly crashes in Ethiopia and Indonesia within a few months. Several countries have banned the plane type from their airspace and many airlines have grounded their 737 Max 8 planes for safety concerns after the Ethiopian Airlines plane crashed minutes after take-off on 10 March. EPA/STRINGER
EPA
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A heap of debris from the wreckage of an Ethiopia Airlines Boeing 737 MAX 8 aircraft are piled at the crash site near Bishoftu, Ethiopia, 13 March 2019. Ethiopian Airlines flight ET 302 carrying 149 passengers and 8 crew was en route to Nairobi, Kenya, when it crashed on 10 March 2019 by yet undetermined reason. All passengers and crew aboard died in the crash. The Boeing 737 Max 8 aircraft has come under scrutiny after similar deadly crashes in Ethiopia and Indonesia within a few months. Several countries have banned the plane type from their airspace and many airlines have grounded their 737 Max 8 planes for safety concerns after the Ethiopian Airlines plane crashed minutes after take-off on 10 March. EPA/STR
EPA
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A crew working with an investigative team to clear the site after the Sunday crash of the Ethiopian Airlines operated Boeing 737 MAX aircraft, carry debris at Hama Quntushele village in the Oromia region, on March 13, 2019. - A Nairobi-bound Ethiopian Airlines Boeing crashed minutes after takeoff from Addis Ababa on March 10, killing all eight crew and 149 passengers on board, including tourists, business travellers, and "at least a dozen" UN staff. Families of the victims were taken to the remote site on March 13, 2019, where the plane smashed into a field with 157 passengers and crew from 35 countries, leaving a deep black crater and tiny scraps of debris. (Photo by TONY KARUMBA / AFP)TONY KARUMBA/AFP/Getty Images
AFP/Getty Images
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FILE PHOTO: An American Airlines Boeing 737 MAX 8, on a flight from Miami to New York City, comes in for landing at LaGuardia Airport in New York, U.S., March 12, 2019. REUTERS/Shannon Stapleton/File Photo
REUTERS
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This picture taken on March 11, 2019, shows debris of the crashed airplane of Ethiopia Airlines, near Bishoftu, a town some 60 kilometres southeast of Addis Ababa, Ethiopia. - An Ethiopian Airlines Boeing 737 crashed on March 10 morning en route from Addis Ababa to Nairobi with 149 passengers and eight crew believed to be on board, Ethiopian Airlines said. (Photo by Michael TEWELDE / AFP)MICHAEL TEWELDE/AFP/Getty Images
AFP/Getty Images
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Family members mourn the victims at the crash site of the Ethiopian Airlines operated Boeing 737 MAX aircraft, at Hama Quntushele village in the Oromia region, on March 13, 2019. - A Nairobi-bound Ethiopian Airlines Boeing crashed minutes after takeoff from Addis Ababa on March 10, 2019, killing all eight crew and 149 passengers on board, including tourists, business travellers, and "at least a dozen" UN staff. Families of the victims were taken to the remote site on March 13, 2019, where the plane smashed into a field with 157 passengers and crew from 35 countries, leaving a deep black crater and tiny scraps of debris. (Photo by TONY KARUMBA / AFP)TONY KARUMBA/AFP/Getty Images
AFP/Getty Images
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A page of a Boeing flight crew operations manual is seen at the scene of the Ethiopian Airlines Flight ET 302 plane crash, near the town of Bishoftu, near Addis Ababa, Ethiopia March 12, 2019. REUTERS/Baz Ratner
REUTERS
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epa07434278 Rescue workers search the site for pieces of the wreckage of an Ethiopia Airlines Boeing 737 Max 8 aircraft near Bishoftu, Ethiopia, 13 March 2019. Ethiopian Airlines flight ET 302 carrying 149 passengers and 8 crew was en route to Nairobi, Kenya, when it crashed on 10 March 2019 by yet undetermined reason. All passengers and crew aboard died in the crash. The Boeing 737 Max 8 aircraft has come under scrutiny after similar deadly crashes in Ethiopia and Indonesia within a few months. Several countries have banned the plane type from their airspace and many airlines have grounded their 737 Max 8 planes for safety concerns after the Ethiopian Airlines plane crashed minutes after take-off on 10 March. EPA/STRINGER
EPA
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A grounded Boeing 737 MAX 8 passenger plane of the Norwegian low-cost airline Norwegian is parked at the tarmac at Vantaa airport in Vantaa near Helsinki, Finland on March 13, 2019. - A number of countries have banned Boeing's 737 MAX 8 medium-haul workhorse jet from their airspace in response to the Ethiopian Airlines crash that killed all 157 people on board. (Photo by Heikki Saukkomaa / Lehtikuva / AFP) / Finland OUTHEIKKI SAUKKOMAA/AFP/Getty Images
AFP/Getty Images
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Rescue workers search the site for pieces of the wreckage of an Ethiopia Airlines Boeing 737 MAX 8 aircraft near Bishoftu, Ethiopia, 13 March 2019. Ethiopian Airlines flight ET 302 carrying 149 passengers and 8 crew was en route to Nairobi, Kenya, when it crashed on 10 March 2019 by yet undetermined reason. All passengers and crew aboard died in the crash. The Boeing 737 Max 8 aircraft has come under scrutiny after similar deadly crashes in Ethiopia and Indonesia within a few months. Several countries have banned the plane type from their airspace and many airlines have grounded their 737 Max 8 planes for safety concerns after the Ethiopian Airlines plane crashed minutes after take-off on 10 March. EPA/STRINGER
EPA
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A heap of debris from the wreckage of an Ethiopia Airlines Boeing 737 MAX 8 aircraft are piled at the crash site near Bishoftu, Ethiopia, 13 March 2019. Ethiopian Airlines flight ET 302 carrying 149 passengers and 8 crew was en route to Nairobi, Kenya, when it crashed on 10 March 2019 by yet undetermined reason. All passengers and crew aboard died in the crash. The Boeing 737 Max 8 aircraft has come under scrutiny after similar deadly crashes in Ethiopia and Indonesia within a few months. Several countries have banned the plane type from their airspace and many airlines have grounded their 737 Max 8 planes for safety concerns after the Ethiopian Airlines plane crashed minutes after take-off on 10 March. EPA/STR
EPA
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A crew working with an investigative team to clear the site after the Sunday crash of the Ethiopian Airlines operated Boeing 737 MAX aircraft, carry debris at Hama Quntushele village in the Oromia region, on March 13, 2019. - A Nairobi-bound Ethiopian Airlines Boeing crashed minutes after takeoff from Addis Ababa on March 10, killing all eight crew and 149 passengers on board, including tourists, business travellers, and "at least a dozen" UN staff. Families of the victims were taken to the remote site on March 13, 2019, where the plane smashed into a field with 157 passengers and crew from 35 countries, leaving a deep black crater and tiny scraps of debris. (Photo by TONY KARUMBA / AFP)TONY KARUMBA/AFP/Getty Images
AFP/Getty Images
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FILE PHOTO: An American Airlines Boeing 737 MAX 8, on a flight from Miami to New York City, comes in for landing at LaGuardia Airport in New York, U.S., March 12, 2019. REUTERS/Shannon Stapleton/File Photo
REUTERS
In a bid to keep costs down, the planemaker presented the differences between the Boeing 737 Max and the previous “NG” version of the jet as minor – with a short tablet-based exercise all that pilots required.
As the new plane was developed, one email read: “If we emphasise MCAS is a new function there may be greater certification and training impact.”
One pilot, whose identity has been redacted, wrote: “I want to stress the importance of holding firm that there will not be any type of simulator training required to transition from NG to Max.
“Boeing will not allow that to happen. We’ll go face-to-face with any regulator who tries to make that a requirement.”
The same individual is thought to have glossed over the existence of MCAS in an email to an airline, writing: “Once the engines are started, there is only one difference between NG and Max procedurally, and that is that there is no ‘off’ position of the gear handle.
“Boeing does not understand what is to be gained by a three-hour simulator session, when the procedures are essentially the same.”
When the airline accepted this assertion, the pilot wrote to a colleague: “Looks like my Jedi mind trick worked again!”
The colleague responded: “Haha, I’ll send you to negotiate peace in the Middle East next.”
When an Asian airline asked for simulator training, it was told that the demand “will be creating a difficult and unnecessary training burden for your airline, as well as potentially establish a precedent in your region for other Max customers”.
Boeing announced this week that it was recommending simulator training for all 737 Max pilots as the jet returns to service.
The internal communications also reveal concerns expressed, often with dark humour, by employees involved with the Boeing 737 Max. One wrote in 2018: ”I haven’t been forgiven by God for the covering up I did last night.”
Peter DeFazio, Republican chair of the House Committee on Transportation and Infrastructure, said: “These newly released emails are incredibly damning.
“They paint a deeply disturbing picture of the lengths Boeing was apparently willing to go to in order to evade scrutiny from regulators, flight crews, and the flying public, even as its own employees were sounding alarms internally.
“Our investigation has uncovered multiple, serious problems with Boeing’s decision-making and the priority that was placed on production and profit over safety.
“But these new emails bring my concerns to an entirely new level. They show a coordinated effort dating back to the earliest days of the 737 Max programme to conceal critical information from regulators and the public.”
Mr DeFazio has demanded an interview with the former Boeing 737 Max chief technical pilot Mark Forkner. In 2015, after a simulator exercise, he complained in a message to a colleague that MCAS was “running rampant in the sim on me”.
Boeing handed over the latest documents in December 2019, shortly before its chief executive, Dennis Muilenberg, was sacked.
The company said: “These communications do not reflect the company we are and need to be, and they are completely unacceptable.
“We regret the content of these communications, and apologise to the FAA, congress, our airline customers, and to the flying public for them.
“The language used in these communications, and some of the sentiments they express, are inconsistent with Boeing values, and the company is taking appropriate action in response.
“This will ultimately include disciplinary or other personnel action, once the necessary reviews are completed.”
Many airlines, including Ryanair, United and Southwest, are not expecting to be flying the Boeing 737 Max before the summer.